GlasCraft Guardian A5-6000 IP Dispensing System
Contents
1. 38 For Your 5 22 E ES ____ ____ E INSIDE BACK COVER The following warnings for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable 51 ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guide lines Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burn2. If you not understand the electrical de scribed above consult your local GlasCraft distributor OR aqualified electrician It is recommended that a qualified licensed electrician should install power to the supply disconnect You should always follow all local or national electrical codes 3 Disconnect power source BEFORE attempting any pairs or opening the Control Boxes Access to internal parts is limited to qualified personnel ONLY Place Main Power Switch in OFF position BEFORE dis connecting power cables This equipment is not approved for use in hazardous locations as set forth in the National Electrical Code Article 500 and Sub Part S of the OSHA Standards Material Or Mechanical Problem Troubleshooting Procedure By following this procedure you should be able to locate and cure problems easily Remember however that a successful operator must know 33 Always Start with step one never skip any portion of these procedures The material pressure gauges are to be used for troubleshooting purposes only The pressures registered on one gauge will not necessarily match the other This difference can be caused by variance in materials temperatures viscosities etc Identify the missing material Check the material pressure gauge on the missing material side a If the missing material gauge reads HIGHER than normal there is RESTRICTION problem between the
3. W 1 Section 1 Installation Equipment Assembly N Main power from power source should be discon nected or turned off to console before making hose connections Trigger Air D 4299 e 6 ut E Q 5 Connect the hose assembly to the unit The swivel fittings on the Hose assembly are sized differently and will attach only one way o UM 6 Connect the yellow heat plug to the outlet on the front of the unit T Connect trigger air line to the air regulator at the system air manifold 8 Connect the thermocouple plug to the outlet on the back of the unit 222224 10 Section 1 Installation Equipment Assembly 9 Continue adding extra hose lengths if necessary GC0705 Extension hose Machine End 6505055 e oda eL The GlasCraft System is factory assembled If 0000000000 gt any questions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact your GlasCraft distributor V N achine End ie Required Tools Opened end wrenches 5 8in 3 4 in 13 16 L V a Lay hoses out straight ELS LI m b Couple hoses together with supplied union fittings and tighten finger tight C Hold crimp fitting hex 3 4 in and union fitting together allowing the hose to hold it s
4. or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitu tion of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verifi cation of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Gracos sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to in
5. ELECTRICAL MALE 6 SM 233 GC1783 CABLE PLUG ELECTRICAL MALE 236 15W687 MODULE HOSE CONTROL GUARDIAN 213 1164 SOCKET RELAY 3 POLE 10AMP Source locally 28 Section 3 General Information Sub Assembly Drawings GC1767 Electrical Assembly 306 307 308 303 310 311 309 Description 301 GC0601 FUSE 2AMP 302 GC0602 FUSE 3AMP 303 RAIL DIN 304 GC0851 CIRCUIT BRKR CIRCUIT DIN RAIL 20 2 305 GC0859 FUSE FUSEHOLDER DIN RAIL 306 GC0863 RELAY FINDER DIN RAIL 16A Source locally 29 Section 3 General Information Sub Assembly Drawings GC1714 GC1715 GC1716 GC1717 Heat Exchanger Assembly 405 417 418 406 Part Description 401 GC0025 PLUG PIPE SOC 1 4 402 GC1748 KIT O RING kit includes 4 403 GC0482 CONNECTOR CONNECTOR 404 GC0554 SCREW BHDC SS 112 40X 188 THERMOMETER THERMOCOUPLE VE LOCITY HIGH ELEMENT HEATER SEE TABLE SWITCH OVERTEMP OPENED SPRING COMPRESSION 86 OD 17 CAP FRONT HEATER DUAL A5 6000 CAP REAR HEATER DUAL A5 6000 HOUSING BODY EXTRUDED HEATER CABLE PLUG ELEC FEMALE 2 LG CABLE PLUG ELEC MALE 2 LG CABLE PLUG ELEC FEMALE 2 SM CABLE PLUG ELEC MALE 2 SM WASHER LOCK SPRING 4 WASHER LOCK SPRING 1 4 SCREW SHDC SS 250 20X1 750 GC1714 5 0891 GC1715 GC0893 405 0559 406 407 GC0962 GC1226 GC1711 GC1712 GC1
6. PRESSURE 3000PSI 2 BACK MT 14 GC1714 HEATER ASSY HEATER DUAL 1 ROD ISO 15 GC1716 HEATER HEATER DUAL ROD 1 POLY 1500 hr CARTASSY 2 1 ze wuRver 25 GC1756 LABEL DECAL GUARDIAN 5 1 6000 IP 6 CONTROL PANEL 28 T WASHER 44 HOSE TUBNG 0 5000D 1 NATURAL 1 4 FT 23 Section 3 General Information Assembly Drawings GC1751 Generic System Schematic 113 see 2 14 6 POLY 0 113 204 6250 20652 oo m 7FU 1 2 18 25 gt 2 1 ood I oz m9 HOSE ry 5 79 2 fu 1 gt mz lt lt AIR MOTOR COUNTER 23 24 25 26 27 28 G 2 C 30 56 64 70 gt 31 TB 32 U sm O gt 2 36 8 U 37 1SSR G 38 58 T 39 2 40 41 m 2 POLY 2CONT 45 46 12 r1 47 lt 48 gt 4o 50 51 16 18 52 lt 54 16 7 56 57 70 gt 58 Z 59 58 g 60 58 61 27 56 57 59 71 N 62 58 lt 63 64 58 28 49 RESET X2 yx X1 30 U 91 6 2 r 66 OT3 191 92 2CR 64 67 28 53 1 2 oroS amp 27 63 65 67 72 68 53 TB 4 69 70 m 3CR 50 RESET 54 91 6 2211 O m 72 E 3CR 73 1 A2 27 68 73 24 L3 L2 L1 1GND 1056 O T3 T2 T1 ings 1 2 4 1 x2 X1 Assembly Dr
7. Proportioning Pumps if applicable D PROPORTIONING PUMPS 1 Determine whether the burst appears on the 5 up or down stroke a If burst appears on UP stroke check UPPER Ball Seat and Cups b If burst appears on DOWN stroke check LOWER Ball Seat Follow the procedures in the order given Remember v that repairs should be made as soon as possible Don t leave the unit open to air any longer than necessary as this will lead to further problems such as moisture entering the system and causing the isocyanate to crystallize After the unit has been exposed to the atmosphere it should be run long enough to displace the material that was in the unit when it was opened up NEVER inspect filter assemblies at time of shut down 4 In troubleshooting a restriction problem where the material pressure gauge on the missing material side is higher than normal start at the point farthest from the unit and work backward Check obvious and easy things first Before performing any repairs on the Gun ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF A GUN 1 Side Block Material Valve turned on 2 Bore hole of Mixing Chamber clean 3 Filter Strainer Screen clean 4 Side hole in Mixing Chamber clean B MATERIAL TEMPERATURE 1 Too high a temperature on resin side can cause a blowing agent to pre expand in either the Hose or the Primary Heater C HOSES 1 Make sure that the Hoses are not p
8. 0211 313273B Fax 612 378 3505
9. 713 GC1773 GC1774 GC1778 GC1781 GC2105 GC2109 GC2151 GC1716 GC0891 GC1717 GC0893 T Not shown 30 Section 3 General Information Maintenance Daily Routine Maintenance 1 Visually inspect the system for leaks 2 Check desiccant dryer to ensure proper functioning Replace dryer beads as necessary 3 Check and lube top of the fluid section Wipe off residual material and add a tablespoon of throat seal liquid TSL Weekly Maintenance 1 Place a small amount of grease on the air motor 2 See related manuals 31 Section 3 General Information Troubleshooting AN Do not place any part of the body in the path of the material spray Do not point the gun at or near other personnel Do not look into the Mixing Chamber orifice at any time Because of the hazardous materials used in this equipment it is recommended that the operator use an air mask goggles protective clothing and other safety equipment as prescribed by current regulations recommendations of the chemical sup pliers and the laws in the area where the equip ment is being used The system will dispense liquid at high pressure when Gun Trigger is activated Read and note WARNINGS contained in this User Manual and the Probler P2 Gun User Manual GC 1386 Polyol will expand the Hose if any normal operating pressures are bled off whenever the mate rial is above approximately 75 degrees F Hot Polyo
10. PHASE BLACK 50 MIN POWER GREEN GROUND 12 Section 2 Operation Start Up Instructions Filling System Never leave machine unattended while system power is on or system is running System running is defined as preheat cycle of the hose heat primary heaters or any pump operation Machine operators must be familiar with the component functions and operation of the machine 1 Adjust air regulator to 20 psi to fill system Air motor will cycle slowly to fill pumps heaters and hoses and stop Pre Operation Check List A Check that all fittings are securely tight B Check electrical hook up qualified electrician recommended C Main power switch on control box should be switched to OFF position D Air regulator turned counter clock wise to OFF position E Hose control and primary heater control to OFF position A Do not place any part of the body in the path of the material spray Do not point the gun at or near other personnel Do not look into the mixing chamber orifice at any time Because of the hazardous materials used in this equipment it is recommended that the operator use PROBLER P2 an air mask goggles protective clothing and other MAKE SURE VALVES ARE OFF safety equipment as prescribed by current regulations recommendations of the chemical suppliers and the laws in the area where the equipment is being used Initial Start Up Procedure With all m
11. TTING 6 JIC x 1 4 GC1719 HANGER PANEL CONTROL GC0242 FITTING 5 8 18 SAE X 1 4 GC1723 COVER HEATER GC1738 FITTING BULKHEAD 1 4 NPT X Source locally 1 4 NPT recom 124 GC1749 MANIFOLD ASSY AIR 1 GC0222 inal GROMMET RUBBER 3 8 THRU GC1720 BRACKET L 1 GC1732 MANIFOLD AIR 133 GROMMET 1 1 2 THRU GC0000 CAP OILER GC2044 WASHER FLAT GC0001 GASKET CAP OILER GC1994 FITTING ELBOW GC2048 WASHER FLAT STD GC2016 FITTING PIPE 137 7 WASHER FLAT STD GC2110 WASHER LOCK SPRING GC2052 WASHER FLAT STD GC2167 FITTING PIPE NIPPLE HEX GC2169 FITTING PIPE NIPPLE HEX GC2109 WASHER LOCK SPRING GC2170 FITTING PIPE NIPPLE HEX GC2110 WASHER LOCK SPRING GC2179 SCREW GC1772 LABEL GLASCRAFT MANIFOLD GRDN OI I NM m NI Section 3 General Information Sub Assembly Drawings Control Panel Assembly 227 220 214 219 213 201 GC0584 COUNTER LCD 202 GC0599 FUSE 1 2 AMP 203 GC0601 FUSE 2AMP 204 15W684 MODULE HEATER CONTROL GUARDIAN 227 GC1626 BLOCK CONTACT NORMALLY OPEN 228 GC1627 BLOCK CONTACT NORMALLY CLOSE 3 GC1779 CABLE PLUG ELEC FEMALE 23 24 25 6 NO 2 NIN O 31 GC1780 CABLE PLUG ELEC FEMALE 232 GC1782 CABLE PLUG
12. USER MANUAL GlaSCF ft DISPENSING EXCELLENCE GUARDIAN A5 6000 IP Dispensing System For use with non flammable foam and polyurea Not for use in explosive atmospheres Maximum fluid working pressure 1600 psi 11 MPa 110 bar Important Safety Instructions Read all warnings and instructions this manual Save these instructions An ISO 9001 Approved Company Table Of Contents Section 1 Installation WV ome 2 E ii uu 5 CA CN ETE _ _____________ 6 E EEA gt 7 zie je IS AS Se UY 8 Section 2 Operation 8 ______ 13 17 Section 3 General Information PASSCINIONY TAINS ___ 21 Um 26 Vus tiated E E E 31 ie sepe u uuu ua E E __ ___ 32 Section 4 Warranty and Reference Information NOTOS u ss u G S uy 35 Liared Warranty PONCY uuu uu EN 37 Technical ASSISIaTICB u
13. al Ratio Material Viscosity Output Operating Temperatures Maximum Air Working Pressure Maximum Fluid Working Pressure Electrical Requirements Compressed Air Requirements Heaters Maximum Hose Length Shipping Weight Overall Dimensions Section 1 Installation Specifications 1 1 Fixed 200 2000 Centipoise Cps AMBIENT Pumps Rated 042 Gallons Per Cycle 159 Liters Per Cycle 32 F 0 C 180 82 C 100 psi 0 69 MPa 6 9 bar 16 1 RATIO 1600 psi 11 MPa 110 bar 50 A 208 240 VAC 50 60 hz Single Phase cable 6 AWG 2 wire and ground Base Unit 1 0 GAL PER MINUTE 17 100 PSI 1 5 GAL PER MINUTE 24 100 PSI 2 0 GAL PER MINUTE 33 100 PSI NOTE As output is increased achieved w chamber size on gun or spray tip pressure drop will be greater Heating capability will also drop 6000 WATT HEATER 200 ft 61 m Each Section 50 ft x 1 4 in 1 0 428 Ibs 194 kg Section 1 Installation Introduction Before operating maintaining or servicing any GlasCraft system read and understand all of the technical and safety literature provided with GlasCraft products If you do not have the proper or related manuals and safety literature for your GlasCraft system contact your GlasCraft distributor In this GlasCraft technical and safety publication the following advisories will be provided where appr
14. als Se pa rate e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean CAUTION e Always clean the fluid inlet strainers after flushing To prevent cross contamination of the equipment s wet ted parts never interchange component A isocyanate Check with your material manufacturer for chemical and component B resin partrs The gun is shipped with compatibility the A side on the left The fluid manifold fluid hous ing side seal assembly check valve cartridge and mix Most materials use ISO on the side but some use chamber are marked on the A side ISO on the B side Epoxies often have amines on the B hardener side Foam Resi ns With 245 fa Polyureas often have amines on the B resin side Blowing Agents New foam blowing agents will froth at temperatures above 90 33 C when not under pressure especially if agitat ed To reduce frothing minimize preheating in a circulation system Section 1 Installation Standard Equipment Model A5 6000 IP Part Description Number p GC1751 A5 6000 IP UNIT 220V 1PH F GCP2R2 PROBLER P2 GUN GC0393 48 FT HEATED HOSE ASSEMBLY GC0319 GRAVITY FEED KIT 313273 USER MANUAL 206995 FLUID TSL 1 QT BOTTLE Purchased Separately Recommended Repair Parts Part Description Number GC1748 HEATER REPAIR KIT Related Manuals Part Description Number p 313277 MATERIAL PUMPS MANUAL Materi
15. anding of the equipment and process resulting in more efficient operation longer trouble free service and faster easier troubleshooting Section 1 Installation Equipment Assembly Guardian Line Installation Guide d You will need to run an air line to the area where the machine will be placed consult the data sheet the specific unit being installed to determine much clean dry air will be needed to supply the machine If the air line is under 25 ft use minimum of 1 2 in 1 0 pipe or hose If the air line is longer than 25 ft use a minimum of 3 4 in pipe or hose Anything smaller than these diameters will severly affect the machine s performance not use quick disconnect fittings the main air line going to the machine GlasCraft Systems are factory assembled If any questions arise concerning air or electrical connections please refer to illustrations located in the forward portion of this User Manual or contact your GlasCraft distributor 1 Locate Guardian a Locate Guardian on a level surface b Do not expose Guardian to rain CAUTION Bolt Guardian to original shipping palet before lifting Check your air compressor to make sure it is capable of supplying the maximum amount of air c Use the wheels to move Guardian to a fixed that the machine requires All GlasCraft equipment location or bolt to shipping pallet and move is rated at 25 CFM cubic foot per minute 708 with f
16. aterial and air lines connected and power cable attached the system is now ready for start up 13 Section 2 Operation Start Up Instructions 3 Place separate clean containers under each indi 6 Clean and lubricate Side Blocks and Seals thoroughly vidual side block Slowly open material valves and re assemble on Gun Make certain that the side black arrow forward on each side block to allow block screws are tightened securely trapped air to escape the hose and material to flow into the containers until all air is purged from the 7 Refer to material manufacturers operating instructions material system for proper preparation of material i e mixers etc 8 Leave Air Regulator at 20 PSI Remember to dispense one to two gallons of material to clear the system of grease and plasticizer that was used during factory testing 4 Close manual material valves Material pressure gauges should now register approximately equal pressure one side registers considerably more pressure than the other side go to the high pres sure side and bleed off some pressure by slightly opening the manual material valve on the side block over the container Bleed pressure until both sides are approximately the same pressure 10 Turn on Hose Control a Push in the green power button b Press up or down arrow buttons on the controller until desired temperature setting is achieved 5 Dispose of waste material properly and in accor danc
17. aw MAIN LIGHT 10 GA BLACK WIRE 18 GA BLACK WIRE 14 GA BLACK WIRE 14 u c a e c 10 GA BLACKWIRE a 220 VOLT SINGLE PHASE ONLY GC1751 System Schematic 220V Single Phase 25 Section 3 General Information Sub Assembly Drawings Cart Assembly IP 130 148 113 130 148 132 134 142 144 Some Parts Removed For Clarity E 154 155 156 118 153 151 152 140 136 Some Parts Removed For Clarity Attach air line for gun here lt N R 108 2 QC SC gt LC ME 130 148 113 113 130 148 133 147 132 1 See Detail A N 136 140 143 107 Detail A 26 Section 3 General Information Sub Assembly Drawings Cart Assembly IP Pat Jav GC0217 FITTING ADAPTER 5 1 4 X 1 4 GC0409 SCREW SS 312 18X 2 750 107 0437 SCREW SET SOC 7 16 20 X 1 3 8 108 RETAINER PLUG VENT 7 RETAINER GC0790 HOSE ASSY 111 GC0999 TRANSFORMER BOX 1 CONTROL GC1040 CONNECTOR 15W209 JACK PANEL CIRCULAR ma Pat ecwns Jav ccoo screw o mue fsew 4 wucoxur T r 153 GC1740 BRACKET RECEPTACLE 1 HOSE GC2207 FI
18. c dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 PARA EFETUAR ENCOMENDAS OU PARA ASSIST NCIA T CNICA contate o seu distribuidor da Graco POUR PLACER UNE COMMANDE OU DEMANDER DU SERVICE contactez votre distributeur Graco PARA REMITIR UN PEDIDO O SOLICITAR SERVICIO p ngase en contacto con el distribuidor de Graco 37 Section 4 Safety Information Technical Assistance Thank You for selecting GlasCraft spray equipment Should you have any questions or need technical assistance contact your factory authorized GlasCraft distributor Distributor Phone Contact For any issues your distributor cannot address the GlasCraft technical service department is always available to assist you with the operation of your spray equipment To help our technical representatives expedite your call and better address your questions please have the following information ready and available when you phone GlasCraft If your questions are not urgent You can e mail all correspondence to service glascraft com For Air Powered Systems Model Air compressor size Serial number CFM generated Type of spray gun Pressure at the system Serial number H
19. cidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MAN UFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment here under or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et pro
20. e with chemical suppliers instructions and local state and federal regulations Before re assembling Side Blocks lubrication can be applied by dabbing a white lithium grease into holes inside of Gun Front Housing and wiping grease over SideBlock Seals Grease will purge itself when air valve is turned on at Gun and Gun is triggered 14 Section 2 Operation Start Up Instructions 11 Turn on the ISO amp POLY Heater control 12 Adjust Main Air Regulator to material suppliers a Push in green power button specifications b Press up or down arrow buttons on the controller until desired temperature setting is achieved Straighten hose out flat to avoid uneven heating and damage to internal wiring of the Hose Assembly Allow enough time for hose to warm up approximately V 15 20 minutes Remember that the heated hose does not have a delta rating The heated hose s func tion is to maintain the heat generated by the primary heaters during system operation and preheat material during initial start up The hose should be set to maintain a temperature close to the set point of the heaters OFF Due to the expansion of urethanes when heated it is imperative that on cold start up of the system that the 14 Relieve any excess pressure by triggering the gun heaters be turned on and allowed to reach operating temperatures before the Main Pump Air Regulator is adjusted to the desired spray press
21. ed T Complete steps 1 6 for all three controllers ISO POLY HOSE Do not change any other settings in the Setup Menu V The settings have been factory programmed for opti mal performance 16 Section 2 Operation Shut Down Instructions Daily Shut Down Procedure 5 Reduce main air regulator pressure to zero 1 Turn off hose and heater controllers 6 Visually inspect the entire system for leaks T Turn off main air supply and main power 3 Flip retract switch to the retract position and trigger the gun until pumps are in the down position 4 Perform gun maintenance See gun manual 17 Section 2 Operation Shut Down Instructions 8 Coil heated hoses with a minimum four foot diameter 2 Use suitable solvent to flush the fluid circuits To to avoid kinking and subsequent damage to the determine the compatibility of solvents with material internal electrical wiring being used Always check with material supplier 9 Check and lube top of the fluid section 3 Increase transfer pump pressure until fluid movement occurs Wipe off residual material and add a tablespoon of throat seal liquid TSL s If fluid movement does NOT occur 100 psi gt gt of air on transfer pumps increase main pump pressure until the main proportioner SLOWLY starts cycling 4 Once primary material is flushed from the system reduce the main air pressure to zero or flip the retract switch to t
22. ent Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equip ment follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely Isocyanate Haza rd To prevent exposing ISO to moisture Always use sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container Keep the ISO lube pump reservoir filled with Graco Spraying materials containing isocyanates creates Throat Seal Liquid TSL Part 206995 The lubricant potentially harmful mists vapors and atomized creates a barrier between the ISO and the atmosphere particulates e moisture proof hoses specifically designed for Read material manufacturer s warnings and ISO such as those supplied with your system material MSDS to know specific hazards and precautions related to isocyanates Never use reclaimed solvents which may contain moisture Always keep solvent containers cl
23. gauge and the Mixing Chamber tip in the Gun b If the missing material gauge reads LOWER than normal there is a STARVATION problem between the gauge and the material supply system lt x Problems may be cyclic in that they will appear first on 2 only one stroke of the Proportioning Pump Check the pressure gauges during one of these bursts of missing materials and always stop spraying while you are getting a burst of good material Concern yourself only with the material pressure on the missing material side In troubleshooting a STARVATION problem where the pressure gauge on the missing material side is LOWER than normal start at the point farthest from the unit and work forward Check the obvious and easy things first Section 3 General Information Troubleshooting A MATERIAL DRUMS 1 Material in drums 2 Material temperature a If the material is to cold especially at the bottom of the drum it will raise the viscosity of the material and stall Transfer Pumps B OPTIONAL TRANSFER PUMP S 1 15 it operating 2 15 air turned on to Transfer Pump 3 Regulated pressure where it should be 4 Severe contamination of pump shaft on isocya nate side This indicates that the pump shaft is not being lubricated Check Filter of Transfer Pump Before diagnosing a faulty Transfer Pump be sure and check all items just listed under Transfer Pump C FILTER ASSEMBLY 1 Check fluid filter at inlet to
24. he retract position and trigger the gun until the pumps are in the down position 5 If the solvent used to flush the system also contains placticizer ensure that all primary material is flushed from the system and close the ball valves the gun 6 Leave the pumps in the full down stroke position with approximately 200 500 psi on the fluid gauges Do not bleed fluid pressure from the system T If plasticizer is required to chase out solvent cycle main pumps until the system is full of plasticizer then close valves and leave the pumps in the full down Extended Shut Down Procedure stroke position with 200 500 psi The following procedure is for long extended shut down periods sA Power should be disconnected and all air regulators turned down to zero 1 Remove side blocks from the gun and relieve pressure from the system PROBLER P2 18 Section 2 Operation Shut Down Instructions 8 Turn off main air supply and disconnect air line from 2 Adjust main air regulator to 20 psi the system 9 Generously coat the exposed transfer pump shafts with lithium grease 10 Coil the heated hoses with a minimum four foot diameter to avoid kinking and subsequent damage to the internal electrical wiring 11 For gun shut down follow the procedure from the gun manual 12 The length of time a system is shut down and the climate conditions it s stored in will determine how often the system sho
25. ion the system will remain shut down until it is manually reset At this point it is necessary to determine if the problem is an over pressure situation When the sensor engages the system will be frozen giv ing you the pressure readings at the time the problem was detected Inspect the fluid pressure gauges in an over pressure situ ation one of the fluid pressure gauges will be significantly higher than the other gauge A When main power to unit is on the console will have wires that are live Disconnect or turn off main power source be fore opening console to make any repairs Before performing any repairs on the system ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED ZERO BLEED OFF 32 Section 3 General Information Troubleshooting WHAT GOOD MATERIAL LOOKS LIKE HOW THE EQUIPMENT NORMALLY OPERATES Over Pressure Problem Correction 1 Determine if the problem is high pressure related WHAT PATH THE MATERIALS FOLLOW THROUGH THE EQUIPMENT 2 Relieve system material pressure KNOWLEDGE OF THESE TROUBLESHOOTING PROCEDURES 3 Turn off main power 4 Fix the problem area a Potential high pressure causes Restriction Overheating material in static position ISO filter at gun 5 Re start system for operation 4 Once the power has been turned off and problem S solved and the main power is turned on again the over pressure lighted buttons will automatically be reset
26. is static sparking or you feel a shock stop operation immediately Do not use equip ment until you identify and correct the problem Keep a working fire extinguisher in the work area PRESSURIZED ALUMINUM PARTS HAZARD Do notuse 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete informa tion about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipm
27. l hoses should never be bled by any method to zero pressure for two reasons 1 The seals in the Gun rely on high pressure to make their seal The high pressure cannot be maintained if the pumps are attempting to apply this pressure through a hose full of expanded froth therefore the Gun seal may leak 2 Re starting immediately after hot Polyol has ex panded in the system may result in spraying sub stantial amounts of bad foam This will continue un til the expanded Polyol in the primary Heater and the Hose has been completely purged Over Pressure System Protection The system incorporates monitors for high pressure monitoring These monitoring devices will prevent the system from continued operation if high pressure situations develop There are pressure sensors located on each propor tioning pump The high pressure sensor is located at the outbound of the fluid section The high pressure monitoring sensor will engage if fluid pressure increases above 2000 psi If a high pressure situation develops the sensor will detect this and immediately engage the hold in circuit This will disengage power to the air motor and will also turn the heaters off On the control box panel there are three yellow lighted push buttons marked over pressure One of these push buttons will be illuminated after the monitoring sensor engages indi cating where the problem is located ISO Poly or Hose In the over pressure situat
28. lugged TROUBLESHOOTING A POOR SPRAY PATTERN To troubleshoot a poor spray pattern you must 5 understand the factors that affect the spray pattern A TEMPERATURE 1 Too warm a material temperature will cause a separation fingering in the pattern 2 Too cold a material temperature will cause a stream effect B PRESSURE 1 Too high a pressure will cause excessive overspray and or separation fingering 2 Too low a pressure will cause a stream effect C CONTAMINATION IN THE MIXING CHAMBER 1 A foreign object in the Mixing Chamber will causea poor pattern Correct problem s immediately 34 Section 4 Safety Information Notes 35 Section 4 Safety Information Notes 36 Section 4 Safety Information Limited Warranty Policy Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited waranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear
29. natural line Using the appropriate wrench A side 3 4 in B side 13 16 in tighten swivel fitting to union not allowing crimp fitting or union to turn Repeat on opposite side of union p N PX AHNXA LN Bx lli i Ele This practice is required on all connection points 1 Hose Q machine 2 Hose gun 3 Adding additional hose sections d Attach the yellow power plugs GC0393 Standard hose Gun End Attach the thermocouple extension cable p n GC0885 11 Section 1 Installation Equipment Assembly 10 Connect the hose assembly to the spray gun as shown 11 All connections should now be tight POLY UY 7 lt Cee UTE S QUA o A When Main Power to system console is on the white and black wires in the console are always live Disconnect or turn off Main Power source before opening console to make any repairs or before making any electrical repair of any type to the system If you do not understand the electrical hook up described above consult your local GlasCraft distributor OR aqualified electrician amp Electrical connections must be checked on gt periodic basis 12 Connect the white and black wires of the Power cord to a single phase of 208 240 VAC 50 60 HZ The green wire should be connected to GROUND 208 240 VAC 50 60 HZ SINGLE
30. opriate Is information about the procedure in progress Is imperative information about equipment protection CAUTION Indicates a hazardous situation that can result in minor or moderate injury N WARNING Indicates a hazardous situation that can result in death or serious injury A ELECTRICAL SHOCK HAZARD Indicates a hazardous situation that can result in electrical shock or serious injury The information in this document is intended only to indicate the components and their normal working relationship typical use Each assembly should be directed by a GlasCraft distributor or made from the GlasCraft Assembly instructions provided This manual provides information for the assembly opera tion maintenance and service of this GlasCraft product as used in a typical configuration While it lists standard specifi cations and procedures some deviations may be found In order to provide our users with the most up to date technology possible we are constantly seeking to improve products If technological change occurs after a product is on the market we will implement that technology in future production and if practical make it available to current users as a retrofit up date or supplement If you find some discrepancy between your unit and the available documen tation contact your GlasCraft distributor to resolve the difference Careful study and continued use of this manual will pro vide a better underst
31. orklift liters at 90 100 psi 62 0 7 MPa 6 3 7 7 bar do not exceed 125 psi 0 86 MPa 8 6 bar d To mount on a truck bed or trailer bolt directly to truck or trailer bed 3 Move material drums to the area that the equipment will 2 Advanced preparation be placed ensuring that they are not sitting directly on the floor Simply place the drums on top of a palate or a Before beginning any installation ensure that the similar device so the drum bottoms will not be in applicator has the desired power supply available contact with any cold surfaces i e 220V single phase 380V three phase within 10 ft of were the machine is to be placed 4 Open all boxes that came with the machine and verify If the machine needs to be further that 10 ft from that all items are accounted for the power supply additional lengths of properly sized electrical cable will be required Never use smaller size than supplied by the factory b Depending on the electrical setup it may be necessary to install an appropriate plug on the end of the cable GlasCraft will not supply this plug as we are unaware of which style will be needed c Consult the data sheet for the specific unit being installed to determine the proper breaker size needed Section 1 Installation Equipment Assembly GRAVITY FEED KIT ss 2 50 BGB B 7 a S D
32. osed when Prevent inhalation of isocyanate mists vapors and notin use atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not Never use solvent on one side if it has been contami available a supplied air respirator is required for nated from the other side everyone in the work area Always park pumps when you shutdown To prevent contact with isocyanates appropriate personal protective equipment including chemically Always lubricate threaded parts with Part 217374 ISO impermeable gloves boots aprons and goggles is pump oil or grease when reassembling also required for everyone in the work area Material Self Ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increas ing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts lization varies depending on the blend of ISO The amount of film formation and rate of crystal the humidity the temperature 3 Keep Components and Changing Materi
33. s and hearing loss This equipment includes but is not limited to Protective eyewear Clothing and respirator as recommended by the fluid and solvent manufacturer Gloves Hearing protection SKIN INUECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Close material shutoff valves and shutoff or disconnect air supply when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help pre vent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there
34. terial Valves 6 Trigger Gun several more times to purge any material remaining in Gun Turn OFF air Switch 7 Unless system is to be returned to service at once follow DAILY SHUT DOWN PROCEDURE 20 Section 3 General Information Assembly Drawings GC1751 Unit Assembly gt TE 5 m d gt e QV A Ec s 257 Some parts been removed for clairty See Detail 21 Section 3 General Information Assembly Drawings GC1751 Unit Assembly Ju Red tubing 46 Blue tubing Receptacle A Receptacle B To Receptacle 22 Section 3 General Information Assembly Drawings GC1751 Parts List Pat Dee a BLIND 0425 ST 5 15520 LABEL WARNNG 112925 SCREW CAP BTNHD GC2368 LABEL MAIN GC0433 SCREW BHDC SS 0 250 20 0 625 GC0805 SWITCH PRESSURE HIGH Source local LABEL LIVEWRE 1 Not Shown secen cowecron 410 SCREW 11N 10 SELFTAP 4 Replacement danger and warning labels tags and cards are available at no cost azi camEPOWwER HFT 1 13 GC1181 GAUGE
35. uld be purged and refilled Usually every 2 4 weeks the following procedure should be followed Purge and Refill Procedure 1 Connect the main air line to the system PROBLER P2 19 Section 2 Operation Shut Down Instructions 5 Open both side blocks simultaneously into separate A containers and dispense approximately 1 1 2 2 gallons of material from each side or until all Before performing any repairs on any part of the system plasticizer is purged from the system Stop the pumps in the down position PLACE ALL CONTROLS ON THE MACHINE AND THE MAIN POWER SOURCE IN THE OFF POSITION AND DISCONNECT THE ELECTRICAL POWER CABLE FROM THE MAIN POWER SOURCE 6 Close both side blocks simultaneously and wipe off residue from the side block seals Regrease and attach both blocks to the gun T Mix and properly dispose of purge material Before performing any repairs on the system ALL AIR and FLUID PRESSURES SHOULD BE RELIEVED TO ZERO BLEED OFF To relieve Air and Fluid pressures System Console 1 Turn OFF valves that supply material to the Pumps 2 Turn OFF Main Air Regulator on Air Motor Gun 1 Open both Side Block Material Valves 2 Turn ON Air Switch 3 Point Gun into a clean suitable container and trigger Gun until material flow stops 4 Fluid pressure gauges must read zero 0 if not trigger Gun until the fluid pressure gauges do read zero 0 pressure 5 Turn OFF Side Block Ma
36. ure If you do not The Emergency Stop Switch is located on the bottom allow the heaters to reach operating temperature before right side of the control Panel when depressed it will adjusting air pressure the material pressure will exceed shut down the power and activate the Air Dump Valve the set point of the over pressure switches causing the To reset turn handle on push button system to shut down 15 The system is now ready for operation 15 Section 2 Operation Start Up Instructions Change Temperature Controller Display 2 Scroll through the Setup Menu by pressing the K Units Fhrenheit or Celsius button until the display reads C F press button 3 times 220 V units are factory set to display temperature readings in degrees Fahrenheit 380 V units are factory set to display 5 Press and hold the button to display the current tempertature readings in degrees Celsius unit setting of C of F The temperature display units can be changed with the fol 4 lowing procedure Continue to hold the button and press the button to switch to the desired unit setting F 1 On the Watlow 5031 controller press and hold the PW and K buttons simultaneously for 3 seconds until the display reads SET This is the Setup Menu 5 Release the SET button 6 Press the infinity button oo to exit the Setup Menu the temperature display unit is now chang
37. ydraulic Pneumatic Is your equipment Dynamic fluid pressure Single phase Three phase ISO POLY What is the inbound voltage Spray gun chamber size to your equipment Material being sprayed Temperature setting ISO Viscosity ISO POLY Temperature setting POLY Approximate material temperature Temperature setting HOSE 38 Giascrart DISPENSING EXCELLENCE Date Purchased Distributor Contact Phone E mail GlasCraft manufactures a complete line of polyurethane foam and polyurea coating spray systems If your application is in plant or a field contractor GlasCraft has a system package to meet your requirements GUARDIAN AIR POWERED A5 amp A6 SERIES EQUIPMENT 6000 OR 12000 WATTS OF HEAT 1600 2200 OR 3000 PRESSURE SET UPS AVAILABLE MH MH Il amp MH HYDRAULIC POWERED SYSTEMS UP TO 45 LBS MINUTE OUTPUT EXCELLENT PERFORMANCE AND RELIABILITY GUARDIAN MMH MOBILE MODULAR HYDRAULIC SYSTEMS SPECIFICALLY DESIGNED FOR ANY TYPE OF SPRAY RIG GIVE COMPLETE UTILIZATION OF FLOOR SPACE IN MOBILE RIG PROBLER P2 SPRAY GUN IMPINGEMENT MIX AIR PURGE OPTIONAL NOZZLE FOR SPRAYING STUD WALLS POURING amp STREAM JET Quality and Performance GENUINE GLASCRAFT GlascrEart DISPENSING EXCELLENCE ADS INC ADVANCED DISPENSE P O 1441 puc MINNEAPOLIS MN 55440 1441 www glascraft com Phone 612 623 6921 Toll Free 1 800 328
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